Mammoet installs six mega modules at Dallas airport

Mammoet self propelled modular transporter (SPMT) carrying one of six prefabricated terminal modules into position at Dallas Fort Worth International Airport’s new Terminal F

Mammoet completed the installation of six prefabricated modules forming the first phase of a project to construct a terminal at Dallas Fort Worth International Airport (DFW) in Texas, USA.

The milestone marks significant progress in a multi-phase project to expand capacity at the busy US hub.

The modules make up the initial section of Terminal F, which is being delivered using modular construction techniques. This method, which involves fabricating large structures off-site and then transporting them for final assembly, is designed to shorten schedules, improve safety and reduce disruption in space-constrained locations such as airports.

For Terminal F, Mammoet worked with Walsh Group, which is leading the Innovation Next+ joint venture to build the 15-gate concourse and new Skylink Station. The operation involved moving the largest airport terminal modules ever transported, with the heaviest weighing 3,320 tonnes and 85 metres long.

Prefabricated modules, weighing up to 3,320 tonnes each, are set in place to form the first phase of DFW’s Terminal F expansion, supported by Mammoet and Walsh Group

The units were built at a fabrication site on airport property and delivered one by one using self propelled modular transporter (SPMT). The transporter was fitted with metal supports, allowing each module to be lifted and carried across the tarmac before installation.

“Modular construction techniques allow construction companies to reduce the scope of work at building sites, and for different structural elements to happen in parallel,” said Reid Whitley, project manager at Mammoet. “This can be incredibly beneficial for sites like airports, where space is limited, and lessening disruption for passengers is critical.”

The project follows similar work by Mammoet at DFW to install a pier-style expansion at Terminal C, which will add nine gates. The next phase will see the company support a comparable expansion at Terminal A.